Foam insert for use with a walking canister system for amputee socket manufacture and associated methods

ABSTRACT

The foam insert is for use in manufacturing a prosthetic socket. The foam insert includes an elongated foam body extending from an open end to a closed end, and configured to be positioned within a rigid canister. The elongated foam body includes a contoured exterior surface configured to transfer pressure through to an interior surface thereof to produce consistent surface contact with a residual limb having casting material thereon. The interior surface of the elongated foam body includes a smooth interior surface configured to interface with the residual limb.

RELATED APPLICATIONS

This application is a Divisional of, and claims priority to, U.S.application Ser. No. 16/943,667 filed Jul. 30, 2020 and titled “WALKINGCANISTER SYSTEM AND DEVICE FOR AMPUTEE SOCKET MANUFACTURE AND ASSOCIATEDMETHODS” which claims priority to U.S. Provisional Application Ser. No.63/006,887 filed Apr. 8, 2020 titled “WALKING CANISTER SYSTEM AND DEVICEFOR AMPUTEE SOCKET MANUFACTURE AND ASSOCIATED METHODS” which isincorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The present invention relates in general to the medical field, and inparticular to prosthetic devices and associated methods.

BACKGROUND OF THE INVENTION

In general, various current techniques involve modeling or measuring anamputee's residual limb (e.g. above the knee or below the knee) viacasting or digitization while the patient is in a static position (e.g.a sitting position), which provides a static model. In other words, bycasting or digitizing in a sitting/static position, a static model isthe result. When such a prosthetic socket is created in a static model,undue pressure and skin breakdown problems are produced on the boneyanatomy of the residuum, primarily the anterior distal end of the tibiaand the fibula head. It should be clear that the orientation of theboney anatomy is not in the optimal or correct position in the currentsocket model approach.

Other techniques include U.S. Pat. No. 5,503,543 to Laghi which isdirected to a prosthetic casting machine that receives an amputatedstump while a patient is standing so that a hard socket can be madebased upon the shape of the stump when it is under load. The patient'sstump is inserted into a liner and the liner is coated with plasterbefore the stump is inserted into the machine. After insertion, whilethe patient is standing, compressed air is introduced into a spacebetween a transparent flexible bladder and a transparent rigid cylinderso that a pressure is applied to the plaster by the bladder.

However, it may be desirable to measure an amputee's residual limb bycapturing the shape in motion to provide an accurate fit, increasedcomfort in the socket, less harm to the patients limb, and more accuratealignment of the relationship between the socket and the foot. If thepatient is measured while upright and/or walking, a more dynamicmeasurement will be captured. By capturing the shape in motion, it takesall three planes into consideration; sagittal, frontal, transverse.Humans are tri-planer beings, so the most accurate measurement and fitis when patient is using all three planes.

This background section is intended to introduce the reader to variousaspects of typical technology that may be related to various aspects orembodiments of the present invention, which are described and/or claimedbelow. This discussion is believed to be useful in providing the readerwith background information to facilitate a better understanding of thevarious aspects and embodiments of the present invention. Accordingly,it should be understood that these statements are to be read in lightof, and not as admissions of, the prior art.

SUMMARY OF THE INVENTION

It is an object of the present embodiments to provide a system, deviceand method to measure an amputee's residual limb by capturing the shapethereof in motion to provide an accurate fit, increased comfort in thesocket, less harm to the patients limb, and more accurate alignment ofthe relationship between the socket and the foot.

This and other objects, advantages and features in accordance with thepresent embodiments may be provided by a foam insert for use inmanufacturing a prosthetic socket, the foam insert including anelongated foam body extending from an open end to a closed end, andconfigured to be positioned within a rigid canister.

The elongated foam body includes a contoured exterior surface configuredto transfer pressure through to an interior surface thereof to produceconsistent surface contact with a residual limb having casting materialthereon. The interior surface of the elongated foam body includes asmooth interior surface configured to interface with the residual limb.

Additionally, and/or alternatively, the contoured exterior surface ofthe foam insert comprises a waffle pattern defining a contoured patternof squares.

Additionally, and/or alternatively, the contoured exterior surface ofthe foam insert comprises a matrix of peaks and valleys.

Additionally, and/or alternatively, the elongated foam body comprises acompressible foam material including a urethane flexible foam.

Additionally, and/or alternatively, the elongated foam body comprises acompressible foam material including a silicone flexible foam.

Other objects, advantages and features in accordance with the presentembodiments may be provided by a foam insert for use in manufacturing aprosthetic socket, the foam insert including an elongated foam bodyextending from an open end to a closed end, and configured to bepositioned within a rigid canister. The elongated foam body includes acontoured exterior surface configured to transfer pressure through to aninterior surface thereof to produce consistent surface contact with aresidual limb having casting material thereon.

Additionally, and/or alternatively, the contoured exterior surface ofthe foam insert comprises a waffle pattern defining a contoured patternof squares.

Additionally, and/or alternatively, the interior surface of theelongated foam body comprises a smooth interior surface configured tointerface with the residual limb.

Additionally, and/or alternatively, the contoured exterior surface ofthe foam insert comprises a matrix of peaks and valleys.

Additionally, and/or alternatively, the elongated foam body comprises acompressible foam material including a urethane flexible foam.

Additionally, and/or alternatively, the elongated foam body comprises acompressible foam material including a silicone flexible foam.

A method of making a foam insert for use in manufacturing a prostheticsocket, the method including providing an elongated foam body extendingfrom an open end to a closed end, and configured to be positioned withina rigid canister, and forming a contoured exterior surface on theelongated foam body to transfer pressure through to an interior surfacethereof to produce consistent surface contact with a residual limbhaving casting material thereon.

Additionally, and/or alternatively, the contoured exterior surface ofthe foam insert comprises a waffle pattern defining a contoured patternof squares.

Additionally, and/or alternatively, the interior surface of theelongated foam body comprises a smooth interior surface configured tointerface with the residual limb.

Additionally, and/or alternatively, the contoured exterior surface ofthe foam insert comprises a matrix of peaks and valleys.

Additionally, and/or alternatively, the elongated foam body comprises acompressible foam material including a urethane flexible foam.

Additionally, and/or alternatively, the elongated foam body comprises acompressible foam material including a silicone flexible foam.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional diagram illustrating a walkingcanister system for manufacturing a prosthetic socket according to anembodiment of the present invention.

FIG. 2 is a schematic diagram illustrating the lower portion of thewalking canister system of FIG. 1 and including the pump, vacuum lines,leg post and floor interface.

FIG. 3 is a top view of the walking canister system of FIG. 1 with thefoam insert, inner chamber wicking material and the suspension bladder(rolled down).

FIG. 4 is a side view of the walking canister system of FIG. 1 mountedon a display platform and with the foam insert, inner chamber wickingmaterial and the rolled down suspension bladder.

FIG. 5 is a side view of the walking canister system of FIG. 1illustrating the suspension bladder rolled up, the outer chamber wickingmaterial, a portion of the canister and the outer chamber suspensionsleeve (rolled down).

FIG. 6 is a side view of the walking canister system of FIG. 1illustrating a portion of the canister and the outer chamber suspensionsleeve (rolled up).

FIG. 7 is a perspective view of an example of a negative cast made withthe walking canister system of FIG. 1 .

FIG. 8 is a perspective view of an example of a positive mold made fromthe negative cast of FIG. 7 .

FIG. 9 is a top perspective view of the foam insert for residual limbcasting used in the walking canister system of FIG. 1 .

FIG. 10 is a front view of the foam insert for residual limb castingillustrated in FIG. 9 .

FIG. 11 is a rear view of the foam insert for residual limb castingillustrated in FIG. 9 .

FIG. 12 is a top view of the foam insert for residual limb castingillustrated in FIG. 9 .

FIG. 13 is a bottom view of the foam insert for residual limb castingillustrated in FIG. 9 .

FIG. 14 is another perspective view of the foam insert for residual limbcasting of FIG. 9 illustrating the positioning on a residual leg.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Those ofordinary skill in the art realize that the following descriptions of theembodiments of the present invention are illustrative and are notintended to be limiting in any way. Other embodiments of the presentinvention will readily suggest themselves to such skilled persons havingthe benefit of this disclosure. Like numbers refer to like elementsthroughout.

In this detailed description of the present invention, a person skilledin the art should note that directional terms, such as “above,” “below,”“upper,” “lower,” and other like terms are used for the convenience ofthe reader in reference to the drawings. Also, a person skilled in theart should notice this description may contain other terminology toconvey position, orientation, and direction without departing from theprinciples of the present invention.

Furthermore, in this detailed description, a person skilled in the artshould note that quantitative qualifying terms such as “generally,”“substantially,” “mostly,” and other terms are used, in general, to meanthat the referred to object, characteristic, or quality constitutes amajority of the subject of the reference. The meaning of any of theseterms is dependent upon the context within which it is used, and themeaning may be expressly modified.

As discussed, prosthetic systems, particularly for lower limbs, includea prosthetic device which is attached to the residual limb via a socketthat is custom shaped to the limb. A liner is generally used to adherethe system to the limb and provide a comfortable transfer of the forcesapplied to the limb. The custom socket is constructed with the aid of amold that is created from a physical casting or optical scanning of thelimb while the limb is relaxed and uninhibited from external stress. Thenegative casting is transferred to a positive mold and the socket istypically constructed with the application of a fiberglass reinforcedthermoplastic layer.

A good fit for the system is determined empirically as the patient wearsthe prosthetic system over a period of weeks to months. The evaluationcriteria include the ability to function, comfort, and consequentialsores or tissue damage to the limb based on both clinical and physicalevidence. Often the results require that a replacement socket beconstructed to adjust the fit.

So, one of the primary issues with fitment which compromises the initialcustom shape of the socket is that the limb being measured is not underthe normal load which would exist during standing or walking. Thecompression of the tissue at the distal end and expansion in other areasof the limb are not taken into account.

Therefore unusual and non-optimal stresses, both compression and shearmay result in discomfort and tissue damage to the limb.

An object of the invention is to provide an approach for measuring thelimb for fitment of the socket while the limb is placed under normalload conditions. The challenges may include: 1) the provision foradjustable counter forces on the outer lateral surfaces of the limb tosimulate the constraints which would be present with the optimum socketshape while the measurement is being made; 2) the ability to performprecision measurement of the limb without interference from the fitmenthardware; and 3) to provide freedom of motion for the patient to movethe limb with a stride of walking to better complete the span ofmeasurements for the limb under an extended range of motion.

Additionally, a below-knee (BK) socket manufacture has approximately 13L codes (the recognized billing code for the healthcare industry). Atthis time, insurance companies are reducing the amount of reimbursementto O & P facilities for durable medical equipment (DME) by at least 30%.Prosthetics fall under the DME category.

Thus, O & P facilities need to find a more cost-effective way to designand deliver a prothesis (e.g. below knee prosthesis) than the currentindustry standard. The average BK prosthesis has at least nine steps.The typical steps may be as follows: measure the patient's residuallimb; pour a negative cast to create a positive mold; modify thepositive mold to reflect the measurements taken by the practitioner;pull a clear thermoplastic material to create a test socket; set thetest socket up on an alignment device with a pylon and foot; walk thepatient to determine the fit of the socket and the establish thealignment between the socket and the foot; then, the test socket may beput into an alignment jig and the test socket is re-poured, whichmaintains the alignment that was established, or if the fit andalignment are unsatisfactory, steps will need to be repeated(unsatisfactory results include, but are not limited to: socket is tooloose; socket is too tight; too much friction; any imbalance, etc.);with the positive mold that has maintained alignment, the definitivesocket is made by either lamination or thermoplastic; and the socket isassembled with the pylon and the foot, then delivered to the patient, aswould be appreciated by those skilled in the art.

With the system, device and method of the present invention, theprosthetic socket may be completed in three steps, instead of the ninesteps discussed above. With insurance companies lowering theirreimbursements to the provider, and patients paying more out of pocketfor their prosthesis, there is a need to lower the cost of the productwhile also improving the quality of the product.

With the present approach, a more accurate and precise measurementserves the patient as well as the practitioner. A patient must take timeoff from work for their multiple appointments to the facility. If theyrely on a caregiver to transport them, that also creates reducedproductivity at a place of employment. An accurate measurement the firsttime reduces the time spent at the facility. Reduced time at thefacility offers the practitioner the ability to see more patients in onework day. This also reduces the materials needed for multiple testsockets. Also, the labor times for technicians per patient is reduced.

Currently, with the above-mentioned current steps, the minimum amount ofappointments at the facility is three, with appointment times varyingfrom 30 minutes to 3 hours each time. With the new approach, it isrealistic and possible to cast a patient, pour a positive mold, createthe test socket, check for fit and alignment, make adjustments and buildthe definitive prosthetic in the same day, in approximately 3 to 4hours, for example.

Referring to the cross-sectional view of FIG. 1 and the drawings FIGS.2-14 , the approach including a system, device and method of the presentinvention is described and illustrated. The example embodiments are bestunderstood from the following detailed description when read with theaccompanying drawing figures. Dimensions may be arbitrarily increased ordecreased for clarity of discussion.

Referring more specifically to FIGS. 1-6 , an example embodiment of awalking canister system 10 (aka ViaWalk™ system) that facilitates thecapturing of the shape of a below-knee (BK) residual limb, under load,while the patient is walking, will be described. Using the walkingcanister system 10, an accurate replication of the boney anatomy anddisplacement of the soft tissue in a natural orientation may beobtained, leading to a dynamically manufactured prosthetic socket.

The walking canister system 10 includes a rigid canister 12 including anopen end 14 at a top, a suspension bladder 16 positioned within therigid canister 12, and an outer chamber wicking material 18 arranged inan outer chamber 20 defined between the suspension bladder 16 and therigid canister 12. A foam insert 22 is positioned within the suspensionbladder 16 and includes a contoured exterior surface 24 configured totransfer pressure through to an interior surface 26 thereof to produceconsistent surface contact with a residual limb, of a walking patient,having casting material thereon. The casting material may typicallyinclude a casting sock 30, casting tape 32 (e.g. C-Form casting tape),and an outer casting sock 34, as would be appreciated by those skilledin the art, and as illustrated in FIG. 1 , for example.

An inner chamber wicking material 40 is arranged in an inner chamber 42defined between the foam insert 22 and the suspension bladder 16. Anouter chamber vacuum port 44 is positioned in the rigid canister 12 andin fluid communication with the outer chamber 20. An inner chambervacuum port 46 is positioned in the rigid canister 12 and in fluidcommunication with the inner chamber 42. An outer chamber suspensionsleeve 48 is configured to extend from the residual limb and over therigid canister 12.

A pylon attachment 50 is located at the bottom of the rigid canister 12and includes a channel 52 in fluid communication with the inner chambervacuum port 46. The channel 52 and inner chamber vacuum port 46 may bedefined by an interlocking plate 54 at the bottom of the rigid canister12. Attachment holes 56 (e.g. four threaded attachment holes) arepositioned at the bottom of the pylon attachment 50. Other approachesfor attaching the rigid canister 12 to a pylon 58 are contemplated aswould be appreciated by those skilled in the art. The pylon 58 isattached to the pylon attachment 50, and a floor interface member 60 ispositioned at a bottom of the pylon 58 and configured to provideconsistent pressure upward through the pylon 58 to the rigid canister 12during a casting-walking process.

The floor interface member 60 is shown as a large rubber stopper thatprovides consistent pressure upward through the pylon 58 to the walkingcanister system 10 during the casting walking process. Other types offloor interfaces may be used, such as a prosthetic foot, as long as thedesired consistent pressure is achieved.

As further illustrated in FIG. 2 , for example, the walking canistersystem 10 may include a vacuum or suction pump 62, corresponding tubing64, valves 66 and couplers 68 to attach to the inner chamber vacuum port46 and the outer chamber vacuum port 44.

This walking canister system 10 may be set in neutral, with no footbeing used, and no other external influence. When the patient walks, thenatural alignment (weight line) of the relationship between a prostheticsocket and the foot of the patient may be established, determined,verified and/or defined in conjunction with the prosthetist's know-howand skill.

The residual limb is casted by using synthetic casting material 30, 32,34 which is wrapped on the residual limb. Once the casting material isapplied, the limb is inserted into the rigid canister 12. The innervacuum chamber 42 of the rigid canister 12 has the foam insert 22, whichis covered with the inner chamber wicking material 40 and the suspensionbladder 16 on the outside of the foam insert 22. The suspension bladder16 is pulled up and over the foam insert 22 to above the knee of thepatient (e.g. as illustrated in FIG. 5 , for example).

Suction or vacuum is then applied (e.g. in a range of −5 to −15 Hg),which starts the initial suspension and compression in the inner chamber42 of the foam insert 22. The outer chamber suspension sleeve 48 isrolled up over the foam insert 22 and suspension bladder 16 and itcreates a seal above the inner chamber 42. Vacuum is applied to theouter chamber 20 (e.g. in a range of −5 to −15 Hg) and createsadditional suction and suspension to prevent any piston action of thelimb in the bottom of the inner chamber 42 and rigid canister 12. Thus,the patient is locked in safely and securely to the walking canistersystem 10, and ready to walk.

The approach is a repeatable process. Multiple users of the walkingcanister system 10 will obtain the same accurate results. The resultsare achieved with the present technology and are not dependent on thecompetency level or experience of the practitioner.

The natural alignment of the patient may vary due to anatomical featuresof the residual limb. The alignment is determined during the castingprocess, by transferring alignment reference line(s) within the innersurface 26 of the foam insert 22 onto the outer surface of the castingmaterial sock 34. The alignment relationship between the socket and footwill be reflected on the negative cast 70 (FIG. 7 ) when it is put ontoan alignment holding device prior to forming a positive mold 80 (FIG. 8) therefrom. The negative cast 70 will reflect the relationship betweenthe manufactured socket and foot because the natural angulation of theindividual's anatomy in the sagittal and frontal planes is preserved.

Referring additionally to FIGS. 9-14 , as illustrated, the foam insert22 (also referred to as a waffle-cone insert) includes a contouredexterior surface 24 with square or rectangular-shaped peaks 90 andvalleys 92 in a matrix configuration. The interior surface 26 ispreferably smooth and with application of the vacuum to the chambers,the contoured exterior surface 24 translates and/or transfers pressurethrough to the interior surface 26 to produce total and/or consistentsurface contact with the residual limb via the cast (casting socks 30,34 and casting tape 32). Other contoured exterior surfaces arecontemplated including, for example, a reverse of the pattern shown, orcircular peaks and valleys in a matrix, etc., as long as the contouredexterior surface 24 creates pressure through to the interior surface 26to produce the desired surface contact with the residual limb via thecast. Of course, the waffle-cone insert 22 as shown may aid in thelongitudinal and latitudinal orientation of the residual limb andresulting socket fit.

Alignment reference line(s) 94 (FIG. 12 ) within the inner surface 26 ofthe foam insert 22 may be transferred onto an outer surface of thecasting material sock 34 during the approach for measuring the limbusing the walking canister system 10. This may aid in the determinationof the natural alignment of the patient during the casting process.

The waffle-cone foam insert 22 is preferably formed using a foammaterial that is compressible and subsequently expandable. Generally,foam is an object formed by trapping pockets of gas in a liquid orsolid. The foam material for the insert 22 should result in the desiredproperties of translating and/or transferring pressure from thecontoured exterior surface 24 through to the interior surface 26 toproduce total and/or consistent surface contact with the residual limbvia the cast during application of the vacuum to the chambers, asdescribed above. Of course, other materials that achieve this goal arealso contemplated.

Solid foams can be closed-cell or open-cell. In closed-cell foam, thegas forms discrete pockets, each completely surrounded by the solidmaterial. In open-cell foam, gas pockets connect to each other. Foamsare examples of dispersed media. Foam can also refer to something thatis analogous to foam, such as quantum foam, polyurethane foam (foamrubber), XPS foam, polystyrene, phenolic, or many other manufacturedfoams. Example foam materials may be provided by Smooth-on, Inc. (e.g.FlexFoam-iT!™ series) including mix and pour, high quality urethane andsilicone foams that are fast curing and used for industrial, militaryand art related applications. Foams expand many times original volume.Flexible foams cure flexible and strong.

The rigid canister 12 may be thermoplastic as shown, or any othersuitable material that provides the rigidity needed to achieve theresults during the walking approach described and shown. The walkingcanister system 10 may be provided in off-the-shelf sizes (e.g. 7 sizesfrom smallest to largest) and also in right and left versions.

The present invention may have also been described, at least in part, interms of one or more embodiments. An embodiment of the present inventionis used herein to illustrate the present invention, an aspect thereof, afeature thereof, a concept thereof, and/or an example thereof. Aphysical embodiment of an apparatus, an article of manufacture, amachine, and/or of a process that embodies the present invention mayinclude one or more of the aspects, features, concepts, examples, etc.described with reference to one or more of the embodiments discussedherein. Further, from figure to figure, the embodiments may incorporatethe same or similarly named functions, steps, modules, etc. that may usethe same or different reference numbers and, as such, the functions,steps, modules, etc. may be the same or similar functions, steps,modules, etc. or different ones.

The above description provides specific details, such as material typesand processing conditions to provide a thorough description of exampleembodiments. However, a person of ordinary skill in the art wouldunderstand that the embodiments may be practiced without using thesespecific details.

Some of the illustrative aspects of the present invention may beadvantageous in solving the problems herein described and other problemsnot discussed which are discoverable by a skilled artisan. While theabove description contains much specificity, these should not beconstrued as limitations on the scope of any embodiment, but asexemplifications of the presented embodiments thereof. Many otherramifications and variations are possible within the teachings of thevarious embodiments. While the invention has been described withreference to exemplary embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe invention. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the inventionwithout departing from the essential scope thereof. Therefore, it isintended that the invention not be limited to the particular embodimentdisclosed as the best or only mode contemplated for carrying out thisinvention, but that the invention will include all embodiments fallingwithin the scope of the appended claims. Also, in the drawings and thedescription, there have been disclosed exemplary embodiments of theinvention and, although specific terms may have been employed, they areunless otherwise stated used in a generic and descriptive sense only andnot for purposes of limitation, the scope of the invention therefore notbeing so limited. Moreover, the use of the terms first, second, etc. donot denote any order or importance, but rather the terms first, second,etc. are used to distinguish one element from another. Furthermore, theuse of the terms a, an, etc. do not denote a limitation of quantity, butrather denote the presence of at least one of the referenced item. Thus,the scope of the invention should be determined by the appended claimsand their legal equivalents, and not by the examples given.

Many modifications and other embodiments of the invention will come tothe mind of one skilled in the art having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is to be understood that the invention is not to belimited to the specific embodiments disclosed, and that modificationsand embodiments are intended to be included within the scope of theappended claims.

That which is claimed is:
 1. A foam insert for use in manufacturing aprosthetic socket, the foam insert comprising: an elongated foam bodyextending from an open end to a closed end, and configured to bepositioned within a rigid canister; the elongated foam body including acontoured exterior surface configured to transfer pressure through to aninterior surface thereof to produce consistent surface contact with aresidual limb having casting material thereon; and the interior surfaceof the elongated foam body including a smooth interior surfaceconfigured to interface with the residual limb.
 2. The foam insertaccording to claim 1, wherein the contoured exterior surface of the foaminsert comprises a waffle pattern defining a contoured pattern ofsquares.
 3. The foam insert according to claim 1, wherein the contouredexterior surface of the foam insert comprises a matrix of peaks andvalleys.
 4. The foam insert according to claim 1, wherein the elongatedfoam body comprises a compressible foam material including a urethaneflexible foam.
 5. The foam insert according to claim 1, wherein theelongated foam body comprises a compressible foam material including asilicone flexible foam.
 6. A foam insert for use in manufacturing aprosthetic socket, the foam insert comprising: an elongated foam bodyextending from an open end to a closed end, and configured to bepositioned within a rigid canister; the elongated foam body including acontoured exterior surface configured to transfer pressure through to aninterior surface thereof to produce consistent surface contact with aresidual limb having casting material thereon.
 7. The foam insertaccording to claim 6, wherein the contoured exterior surface of the foaminsert comprises a waffle pattern defining a contoured pattern ofsquares.
 8. The foam insert according to claim 7, wherein the interiorsurface of the elongated foam body comprises a smooth interior surfaceconfigured to interface with the residual limb.
 9. The foam insertaccording to claim 6, wherein the contoured exterior surface of the foaminsert comprises a matrix of peaks and valleys.
 10. The foam insertaccording to claim 6, wherein the elongated foam body comprises acompressible foam material including a urethane flexible foam.
 11. Thefoam insert according to claim 6, wherein the elongated foam bodycomprises a compressible foam material including a silicone flexiblefoam.
 12. A method of making a foam insert for use in manufacturing aprosthetic socket, the method comprising: providing an elongated foambody extending from an open end to a closed end, and configured to bepositioned within a rigid canister; and forming a contoured exteriorsurface on the elongated foam body to transfer pressure through to aninterior surface thereof to produce consistent surface contact with aresidual limb having casting material thereon.
 13. The method accordingto claim 12, wherein the contoured exterior surface of the foam insertcomprises a waffle pattern defining a contoured pattern of squares. 14.The method according to claim 13, wherein the interior surface of theelongated foam body comprises a smooth interior surface configured tointerface with the residual limb.
 15. The method according to claim 12,wherein the contoured exterior surface of the foam insert comprises amatrix of peaks and valleys.
 16. The method according to claim 12,wherein the elongated foam body comprises a compressible foam materialincluding a urethane flexible foam.
 17. The method according to claim12, wherein the elongated foam body comprises a compressible foammaterial including a silicone flexible foam.